Forming a lead acid bipolar battery electrode having a peripheral sealing frame and relevant product

Abstract

The method of forming the battery electrode includes providing two complementary half-frames of plastic material each having a substantially flat face delimited by an outer closed line and an inner closed line, where the inner and outer closed lines enclose the perimeter of the plate. Next, a plate is placed within a pressure forming mold between the two half-frames so as to enclose the perimeter of the plate between the outer closed lines and the inner closed lines. Then the mold is closed and heated to a temperature causing the plastic material of the half-frames to fuse and adhere continuously along the entire perimeter of the plate.

We claim: 
     
       1. A method of forming a continuous peripheral frame integral with a plate of electrically conductive material constituting an electrode of a bipolar battery, in which the frame constitutes a modular peripheral member for joining to equal adjacent members, thereby hermetically sealing the cells of the battery, the method comprising the steps of: a) providing two pro-formed complementary half-frames of a plastic material each having a flat face delimited by an outer closed line and an inner closed line, said inner and outer closed lines enclosing the perimeter of the plate;   b) placing a conductive plate within a pre-heated pressure forming mold, said conductive plate being interposed between the flat faces of the two half-frames to grip a perimeter of the conductive plate between the outer closed lanes and the inner closed lines;   c) closing the mold;   d) heating the mold to a temperature to cause the plastic material of the flat faces of the half-frames to fuse and adhere to the conductive plate along an entire perimeter of the conductive plane;   e) applying pressure to squeeze the half-frames together;   f) cooling the mold;   g) opening the mold and drawing a finished workpiece including an electrode with a peripheral frame.   
     
     
       2. The method of claim 1, wherein the plastic material is a polyolefin based material comprising polar units to chemically bind to the conductive plate. 
     
     
       3. The method of claim 1, wherein the half-frames are disposed to be symmetrical about to a central plane of the conductive plate. 
     
     
       4. The method of claim 1, wherein the flat faces comprise outer parts forming steps for accommodating the conductive plate. 
     
     
       5. An electrode for a bipolar battery, of the type consisting of an electrically conductive plate, a peripheral, continuous frame being securely fixed to the outer edge of the plate, said frame constituting a modular peripheral member providing junction to equal adjacent members for hermetically sealing the cells of the battery, the electrode being formed from the method comprising the steps of: a) providing two pro-formed complementary half-frames of a plastic material each having a flat face delimited by an outer closed line and an inner closed line, said inner and outer closed lines enclosing the perimeter of the plate;   b) placing a conductive plate within a pre-heated pressure forming mold, said conductive plate being interposed between the flat faces of the two half-frames to enclose a perimeter of the conductive plate between the outer closed lines and the inner closed lines;   c) closing the mold;   d) heating the mold to a temperature to cause the plastic material of the half-frames of the flat faces of the half frames to fuse and adhere to the conductive plate along an entire perimeter of the conductive plate;   e) applying pressure;   f) cooling the mold to a drawing temperature;   g) opening the mold and drawing a finished workpiece including an electrode with a peripheral frame.   
     
     
       6. A method of forming a continuous peripheral frame integral with a plate of electrically conductive material adapted to constitute an electrode of a bipolar battery, in which the frame constitutes a modular peripheral member for joining to equal adjacent members, thereby hermetically sealing the cells of the battery, the method comprising the steps of: providing two pro-formed complementary half-frames of a plastic material each having a flat face delimited by an outer closed line and an inner closed line, said inner and outer closed lines enclosing the perimeter of the plate, wherein the flat faces comprise outer parts forming steps for accommodating the conductive plate;   placing a conductive plate within a pre-heated pressure forming mold, said conductive plate being interposed between the flat faces of the two half-frames to grip a perimeter of the conductive plate between the outer closed lines and the inner closed lines, the half-frames being symmetrical about the conductive plate;   closing the mold;   heating the mold to a temperature to cause the plastic material of the flat faces of the half-frames to fuse and adhere to the conductive plate along an entire perimeter of the conductive plate;   applying pressure to squeeze the half-frames together;   cooling the mold;   opening the mold and drawing a finished workpiece including an electrode with a peripheral frame.